Binder composition



P e 1 19 0"I Bnv'nEnooMPosrrIoN Earl George K ernCliifside Park, N. J., assignor to The BarrettCompany', New York, N. Y. a corporation of New Jersey No Drawing. Application March 2,1937, Serial N0.128,63 4=v claims. (01. 260-28) This invention relates to binder compositions and more particularly to binders employed in the manufacture of tile us'e'cl'in construction of floors, walls, roofs, etc.', and to the resultant tile product;

In the "manufacture of tilefbinders such as asphalt or blends of paracou'maroneor related resins and stearinepitch are; mixed'with suitable fillers such, for example, as wood-flour, asbestos fiber, otherfibrous material, clay, or otherinert material and the mixture moulded-to shape to produce the desired product. Blends of paracoumarone resin and stearine pitch have found wide application for this 3 purpose 'because such blends have the necessary adhesive properties and result in tile having-physical properties and ageing characteristics which, while not altogether satisfactory, are as good as or better than those of tile made with other binders hitherto practically available} Stearine pitch, however, is subject to oxidation on exposure to air, and tile containing it -tend "to become br'ittle'andfrequently shrink or warp-"on storage owing to oxidation of the stearine pitch. I

It is an object of this invention to provide a binder particularly adapted for use in'the manufa'cture' of til-e,-which binder will not readily oxidize on exposure to air and which possesses other desirableproperties rendering it admirably 'suitedfor such use; Otherobjects and "advantages of this invention-will be made'evident as the description of the invention progresses.- j

I have discovered that pinefatty acid pitch blended with paracoumarone resin-in suitable proportions gives a binder which is eminently satisfactory for u se in tile manufacture. *This binder is not readily oxidized as is the case-with binders heretofore used and with which I am familiar, and has the necessary adhesive and elastic properties which render it particularly useful in the manufacture of tile. Moreover, I have discovered that pine fatty acid pitches soften and toughen paracoumarone resin without greatly increasing the temperature susceptibility of the resultant blended binder, i. e., the melting point of the resultant composite binder will not be reduced to a point where the binder bleeds or softens when subjected to temperatures normally encountered by the finished tile in use. As compared with paracoumarone resin alone, the composite binder improves the toughness and reduces the brittleness of the tile, even at the lowest temperatures encountered in normal use thereof. A further advantage of pine fatty acid.

pitch over other materials heretofore common- 1y blended with paracoumarone or similar resins is that it fluxes morereadily such of these resins as are difficultlysoluble in oils. Hence. the,

use of pine fatty acid pitch; results-in a more. in

homogeneous binder.. The binder of this invention results in a tile which weathers 'betterowing to the less brittle characteristics thereof-and to its: greater resistance to oxidation, with. ,conse quent less likelihood of the tile being broken, or chipped'in application and use than time made with other binders such as .the paracoumarone .resin-stearine-pitch, binder heretofore common-.

1y used.

I have made the further surprising discovery vel'oping my inventi'omthat it is' hlot necessary to replace all of the stearine pitch of previous for mulas with pine'fatty "acid pitch in order to as a result of extensive experimental work indeobtain the beneficial results of thelatter. For I example, a binder containing 40% stearine pitch and no 'pine fatty acid pitch'w'as' found unsatis factory,"whereas by replacing 15 partsfofth efilo parts of the stearine pitchwith pine fatty acid made with it did'not warp or shrink: One 'possible explanation of this surprising result which occurs to me,- based .on theworksI have :Jd'one in this field, is that the pine fattyv acid pitch-conpitch, a satisfactory binder resulted-1.; e., tiles i tains. a protective agent-or anti-oxidant'which prevents or suflicientlyiminimizes deleterious oxidation of the 'stearine pitch to yielda satisfactory binder. I g,

Pine wood fatty acid pitch may. be obtained by working up th'eresinous material removed. from pine wood in the manufacture of paper or pulp in accordance with wellknown procedures practiced in.making..-paper from such wood. 1f'his resinous material is distilled, under vacuum and with the aid of steam if desired, to remove dis tillates including abietic acid rosin, leaving a residue of pine fatty acid pitch which is employed in the manufacture of the binder of this invention. The melting point of thepine fatty acid pitch used may fall within the range of about to 140 F.; preferably a pitch having a melting point of about 100 F. is used.

A minor amount of the .pine fatty acid pitch is blended with a major amount of the paracoumarone resin having a melting point of from about 194 to 320 preferably about 250? F. in the proportion'of from 50% to resin to 50% to 20% pine'fatty acid pitch, the resultant binder mixed with the filler and the mixture moulded 1 to produce the desired hardtile product. vPreferably' the blending isaccomplished by melting the paracoumarone resin by heating it andthen adding the pin'e'fatty acid pitch to the melted resin as fast as it dissolves therein. In one ex- ]ample of making the binder of this invention in this'manner 66%% of paracoumarone resin of 245 Fflm eltin'gfpoint was blended with 33! pine fatty acid'pitch of about 122 F. melting point to produce an eminently satisfactory tile binder of 18,7 F. melting point,

lParaboumarone resin is ordinarily made by the 10.

sulfuric-acid polymerization of coal tar. or water gastar naphtha fractions containing coumarone, indene and associated polymerizable compounds. Other polymerization methods maybe used. ,Naphthas from cracked gasoline or from fatty acid pitch being equalto'at least of the amount of stearine pitch.

Li I

An example of asatisfactorybindercontaining both stearine and pine fatty acid pitches follows: 1

- Per cent Paracoumarone resin, melting point 245 F 60 Pine fatty acid pitch, melting point 105 F Stearine pitch, 147 F Melting point of binder, 196F.

Tile made with the binder of .this invention may contain about binderand 70% filler material which may be constitutednof Per cent Long fibered asbestos 20 Short flbered asbestos Finely divided (air floated) silica 10 Pigment, e. g. red oxide of ironfor a red tile- 5 The percentage figures in the above table are in terms of per cent of each ofthe filler constituents based on the total constituents of the tile. The above data represent a typical formula for a tile containing the binder of this invention andyit will be understood; considerable variation in the proportions is permissible. For example, from '25 to 35% binder may be used; the amount of long fibered asbestos may be reduced to 15% and in some cases to as low as 10%. The long fibered asbestos is a strength imparting constituent, and since it is considerably more expensive than the other constituents, the amount thereof is kept aslow as possible compatible with a satisfactory tile. The silica acts to fill the interstices in the fibrous portion of the filler and has a beneficial effect when the mixture is milled in that it aids in the elimination of air from the mix and consequently avoids formation of blisters in the final product.

The pigment and fibrous material may be added to the binder in a suitable mixer in which heat is maintained and the mixing continued until a tough homogeneous plastic mass is obtainedf. From the mixing machine the plastic mass is fed between a pair of milling rolls where the mix is milled to remove blisters therefrom.

- From the milling rolls the mass in sheet form is fed, through calendar rolls where it is reduced to the desired thickness. The resultant sheet is then fed through dieing equipment where tiles of the desired shape are produced.

.-It is to be understood this invention is not restricted to the present disclosure otherwise than defined by the appended claims.

What is claimed is: I 1. 'Ahornogeneous composition suitable for use as a'binder comprising pine fatty acid pitch and naphtha resin.

2. A homogeneous binder suitable for use in the manufacture of tile comprising pine fatty acid pitch blended with paracoumarone resin. 3. A homogeneous binder suitable for' use in the manufacture of tile consisting of pine fatty acidpitch blended with paracoumarone resin.

, 4. A homogeneous binder suitable for use in the manufacture of tile comprising 20% to of pine fatty. acid pitch blended with to 50%-naphtharesin.

5. A homogeneous binder suitable for usef in the manufacture of tile comprising 80% to 50% paracoumarone-resin having a meltingpoint of from 194 to 320 F., blended with 20% to 50% pine fatty acid pitch having a melting point of from70t6140;F. Y

6. A homogeneous binder suitable for use in the manufacture of tile consisting of about 33%% pine fatty acid pitch having a melting point of about 122? F, blended with about 66%% paracoumarone resin having a melting'point of about 245 F. I

, '7. A tile comprising filler material and a binder comprising pine may acid pitch blended with naphtha resin.

8. A tile comprising filler material and abinder comprising a major amount of paracoumarone resin having a melting point of from 194 to 320 F. and a minor amount of pine fatty acid pitch having a melting point offrom 70 to F.

9. A homogeneous binder composition suitable for-use in the manufacture of floor tile comprising ,a blend of paracoumarone resin, pine fatty acid pitch and stearine pitch.

EARL GEORGE KERR. 

